CN102159374B - Process for producing multilayered molded article and mold set for multilayered molded article - Google Patents

Abstract

A technique for multilayer molding is provided in which when a second resin layer is formed by injecting a resin into a cavity located on one side of an interlayer fused on the other side to a first resin layer, gate-area shifting in the interlayer and remelting of the primary molded article can be more effectively inhibited. The technique comprises: a first step in which a primary molded article comprising an interlayer (5) and a first resin layer (4) fused to one side thereof is supplied; and a second step in which a second resin layer (23) is formed by injecting a resin into a cavity located on the other side of the interlayer (5). A protrudent part (5a) which projects outward from the multilayered molded article and is in contact with a supporting mold (1B) for the primary molded article is formed beforehand on the periphery of the interlayer (5) or first resin layer (4) so that in the step of second-resin injection, the resin is injected into the cavity (6) through a channel facing the protrudent part (5a).

Description

The manufacture method of multilevel shaping product reaches the die set for the multilevel shaping product

Technical field

The present invention relates to the manufacture method of the multilevel shaping product that formed by the various kinds of resin combined shaping and the die set that the method is used.

Background technology

As the invention relevant to the multilevel shaping product, following patent documentation 1 is arranged.In the invention of patent documentation 1 record, the series of processes be implemented as follows: by movable type (cavity mold) matched moulds to the 1st fixed mould (the 1st core pattern) that is provided with the transparent Surface sheet be shaped in advance in recess, back-welding shape by the 1st cast gate injection the 1st resin at Surface sheet goes out the once-forming product, and carry out a die sinking, when the once-forming product are remained on to movable type, make the 2nd fixed (the 2nd core pattern) slide and move to movable type, and make the 2nd fixed and movable type matched moulds, back-welding shape by the 2nd cast gate injection the 2nd resin at the once-forming product goes out the secondary forming product, again carry out die sinking, the multilevel shaping product that obtain are taken out from mould.

According to said structure, owing to can making at the back side of transparent Surface sheet once-forming product and secondary forming product become stacked state, so undertaken painted by any one party in once-forming product and secondary forming product, thereby can hide the inside of main body, in addition, the once-forming product also adopt transparent material, can make following secondary forming product become the form of being had an X-rayed.

Patent documentation 1: TOHKEMY 2005-66834 communique

Yet, by the shape of research mould or the operation of injection, also can be between the 1st resin bed and the 2nd resin bed, the intermediate layer in advance be shaped to embed the shape setting.For example, adopt transparent material if be configured in the once-forming product at the back side in intermediate layer, and configure suitable color or pattern in intermediate layer, can be through color or the pattern in once-forming product visual confirmation intermediate layer, thereby the appearance design with depth sense can be provided, become the product that aesthetic property is good.Even there is no color or pattern in intermediate layer, due to once-forming product, intermediate layer and secondary forming product, this is three folded layer by layer, so strength increase physically, durability improves.

In addition, in between once-forming product and secondary forming product, the structure in intermediate layer being set, when the injection of the 2nd resin, the heat of the 2nd resin is directly to the transmission of once-forming product and the state transfer to be cushioned by intermediate layer, thereby brought into play, suppresses the effect of once-forming product because of the heat phenomenon that melting becomes inhomogeneous again that is subject to from the 2nd resin.

But, between once-forming product and secondary forming product, arrange while thering is the intermediate layer (decorative layer) of pattern, when the resin injection of secondary forming, can occur intermediate layer because of heat again the phenomenon of melting be that so-called cast gate shifts.So-called cast gate shifts and refers to, when the resin of the secondary forming of high temperature (250 ℃～280 ℃) contacts with intermediate layer, the heat of this resin is transmitted to intermediate layer, but this heat is difficult to the mould transmission because of the effect of heat insulation of once-forming product, thereby intermediate layer becomes high temperature melting, the phenomenon that pattern fluidly is out of shape.

In addition, the once-forming product are the phenomenon of melting again, can't merely by only between once-forming product and secondary forming product, intermediate layer being set, stop fully, for stoping fully, need to make the once-forming product thicken, thereby also have the abundant little problem of the thickness that can not make the multilevel shaping product.

Summary of the invention

The present invention In view of the foregoing researches and develops, its objective is manufacture method that a kind of multilevel shaping product are provided and such multilevel shaping mould, while to the die cavity resin by injection of another surface configuration in the intermediate layer with the 1st resin bed hot adhesion, forming the 2nd resin bed, the phenomenon of the cast gate transfer in intermediate layer can be suppressed, or the melting again of once-forming product can be more effectively suppressed.

The First Characteristic structure of the manufacture method of multilevel shaping product of the present invention is, these multilevel shaping product have the 1st resin bed and the 2nd resin bed that clips intermediate layer and configure, and its manufacture method is characterised in that,

Have:

The 1st operation, the once-forming product that provide described the 1st resin bed hot adhesion to form on a surface in described intermediate layer in this operation;

The 2nd operation forms described the 2nd resin bed to another the surperficial die cavity resin by injection that is configured in described intermediate layer in this operation,

In described intermediate layer or the peripheral part of described the 1st resin bed, be formed with outstanding to the outside of multilevel shaping product and with the protrusion tab of the support type butt of described once-forming product,

In described the 2nd operation, described resin is injected into described die cavity via the stream towards described protrusion tab.

In addition, multilevel shaping of the present invention by the First Characteristic structure of mould is,

A kind of die set, it is used in following multilevel shaping product: there is the 1st resin bed and the 2nd resin bed that clip the intermediate layer configuration, it is characterized in that,

Have: the 1st mould, its once-forming product that can form on a surface in described intermediate layer described the 1st resin bed hot adhesion are supported; The 2nd mould, it is formed for the die cavity of described the 2nd resin bed in another face side in described intermediate layer,

Described the 1st mould has support, and this support, when described the 1st mould and described the 2nd mould matched moulds, is supported the protrusion tab of the peripheral part that is formed on described intermediate layer or described the 1st resin bed,

Be configured to comprise the position towards described protrusion tab for the stream to described die cavity resin by injection.

According to these feature structures, the Er Yu intermediate layer, space that the 2nd resin be injected into presss from both sides by the type by protrusion tab and a side contacts.Now, even the 2nd resin of high temperature contacts with intermediate layer, the heat of the 2nd resin is transmitted to intermediate layer, and due to the heat in intermediate layer, by protrusion tab, the type to opposite side easily transmits, so intermediate layer also is difficult to become high temperature.In addition, especially in the situation that protrusion tab is arranged at intermediate layer, the heat that protrusion tab from from the 2nd resin to intermediate layer transmits, at first along the width of protrusion tab, expand, be delivered to again the main body in protrusion tab intermediate layer in addition, thereby with without protrusion tab, from the heat of the 2nd resin, directly to the situation of the main body transmission in intermediate layer, compare, the part in intermediate layer is difficult to become high temperature.Thus, can prevent the melting in intermediate layer or the distortion of pattern (cast gate transfer).Especially, near the position protrusion tab in intermediate layer easily becomes high temperature, the easy melting in intermediate layer, and near heat type transmission to opposite side by protrusion tab of the position this protrusion tab can suitably prevent the melting in intermediate layer thus.

In addition, according to these feature structures, not only between once-forming product and secondary forming product, intermediate layer is set, also by protrusion tab, the type to opposite side conducts heat the heat of the 2nd resin, because the heat that is delivered to the once-forming product reduces, so the once-forming product phenomenon of melting are again stoped fully, its result can make the thickness of multilevel shaping product fully little.

Other feature structure of the present invention is, in the manufacture method of multilevel shaping product of the present invention, in described the 2nd operation, to carry out the injection of described resin under the state of the edge of having fixed described protrusion tab.

According to this feature structure, when the 2nd resin injection, can prevent the dislocation of decorative layer and produce floating or perk of decorative layer.Thus, due to contacting of the type that can maintain well protrusion tab and opposite side, so the heat energy of decorative layer enough by protrusion tab reliably to the type transmission of opposite side.Thus, can prevent reliably the melting of decorative layer.

Other feature structure of the present invention is with in mould, to clamp and fix the edge of described protrusion tab at multilevel shaping of the present invention by described movable type and described the 2nd fixed.

According to this feature structure, owing to clamping by movable type and the 2nd fixed and fixing protrusion tab, so can prevent from skidding between movable type and the 2nd fixed and protrusion tab, when the 2nd resin injection, can further prevent the dislocation of decorative layer and produce floating or perk of decorative layer.And, when movable type and the 2nd fixed matched moulds, due to by movable type and the 2nd fixed clamping protrusion tab, the structure of clamping protrusion tab etc. can be set in addition, simplification that can implementation structure.

Other feature structure of the present invention is that described fixed cell is that the mode to grip described edge based on described matched moulds is arranged on the pressure contact portion on described the 1st mould and described the 2nd mould.

According to this feature structure, with the matched moulds of the 1st mould and the 2nd mould fixing edge of protrusion tab automatically and reliably accordingly, thereby can suppress more reliably floating or perk of decorative layer.

Other feature structure of the present invention is, the inlet portion towards the position of the described stream of described protrusion tab with respect to described die cavity connects with linearity; And in described the 2nd operation, under the state be connected with this die cavity along described die cavity at the described stream towards described protrusion tab, along the bearing of trend resin by injection of described protrusion tab.

According to this feature structure, the 2nd resin be injected into does not flow swimmingly and enters die cavity along these positions in intermediate layer contiguously with protrusion tab and the main body section head-on crash ground in intermediate layer.Therefore, Yi Bian contact with intermediate layer head-on crash ground the structure that enters die cavity on one side with the resin that is injected into, compare, because resin can not precipitate near intermediate layer in generation, so intermediate layer is difficult to be subject to the impact of the heat of resin.

Other feature structure of the present invention is, in the described intermediate layer by the 1st mould supporting be configured between the decorating film of inner surface of the 2nd mould and be formed with described die cavity, at the clip for described decorating film being fixed on to described the 2nd mould, be arranged on the position contacted with the base end part of described protrusion tab; And, in described the 2nd operation, be arranged under the state of the position contacted with the base end part of described protrusion tab resin by injection at described clip.

According to this feature structure, be crimped to the position at the position of the main part that is loaded into final formed products that is about to become decorating film to the 2nd mould by clip due to decorating film, so the phenomenon that decorating film floats from the recess inner surface of the 2nd mould is also suppressed, can access the good formed products of quality.

Other feature structure of the present invention is, the stair-stepping recess for the front end of the described protrusion tab of accepting to be formed at described intermediate layer, be arranged on described the 1st mould; And, in described the 2nd operation, keep out of the way under the state that is arranged on the stair-stepping recess on described support type resin by injection at the front end of the described protrusion tab that is formed at described intermediate layer.

According to this feature structure, the front end of the protrusion tab in intermediate layer is protected by this stair-stepping recess, can prevent thus because of the floating or " perk " etc. of the mobile intermediate layer caused of resin, and obtain the good formed products of quality.

The accompanying drawing explanation

Fig. 1 is the unitary side cutaway view that the multilevel shaping in the first embodiment is used mould.

Fig. 2 is the unitary side cutaway view that the multilevel shaping in the first embodiment is used mould.

Fig. 3 is the unitary side cutaway view that the multilevel shaping in the first embodiment is used mould.

Fig. 4 is the unitary side cutaway view that the multilevel shaping in the first embodiment is used mould.

Fig. 5 is the cutaway view along the I-I direction of arrow in Fig. 3.

Fig. 6 is the cutaway view along the I-I direction of arrow in Fig. 5.

Fig. 7 is the overall perspective view of the multilevel shaping product in the first embodiment.

Fig. 8 is the unitary side cutaway view that the multilevel shaping in the second embodiment is used mould.

Fig. 9 is the unitary side cutaway view that the multilevel shaping in the second embodiment is used mould.

Figure 10 is the unitary side cutaway view that the multilevel shaping in the second embodiment is used mould.

Figure 11 is the unitary side cutaway view that the multilevel shaping in the second embodiment is used mould.

Sectional view when Figure 12 is movable type in the second embodiment and the 2nd fixed matched moulds.

Flat cutting view when Figure 13 is movable type in the 3rd embodiment and the 1st fixed matched moulds.

Figure 14 is the cutaway view along the II-II direction of arrow of Figure 13.

Figure 15 is the cutaway view along the I-I direction of arrow of Figure 13.

Flat cutting view when Figure 16 is movable type in the 3rd embodiment and the 2nd fixed matched moulds.

Figure 17 is the cutaway view along the IV-IV direction of arrow of Figure 16.

Figure 18 is the cutaway view along the III-III direction of arrow of Figure 16.

Figure 19 is the overall perspective view of the multilevel shaping product in the 3rd embodiment.

Sectional view when Figure 20 is movable type in other embodiments and the 1st fixed matched moulds.

Sectional view when Figure 21 is movable type in other embodiments and the 2nd fixed matched moulds.

Figure 22 is the unitary side cutaway view that the multilevel shaping in the 4th embodiment is used mould.

Figure 23 is the unitary side cutaway view that the multilevel shaping in the 4th embodiment is used mould.

Figure 24 is the unitary side cutaway view that the multilevel shaping in the 4th embodiment is used mould.

Figure 25 is the unitary side cutaway view that the multilevel shaping in the 4th embodiment is used mould.

Figure 26 is near the partial enlarged drawing the 1st cast gate in Figure 23.

Figure 27 is near the partial enlarged drawing the 2nd cast gate in Figure 23.

Figure 28 means the stereogram of the 2nd fixed in Figure 22.

Figure 29 is the sketch of the secondary forming product that obtained by the 4th embodiment.

The specific embodiment

(the first embodiment)

Below, multilevel shaping of the present invention is described with mould.

Multilevel shaping mould of the present invention is only to show the mould that a part of multilevel shaping machine has in figure, as shown in Figure 1 to 4, it has the 1st movable type 1A and the 2nd movable type 1B (being all an example of the 1st mould), reaches the 1st fixed 3 and the 2nd fixed 7 (example of the 2nd mould).

Fig. 1 means a certain state that movable type 1A, 1B separate from fixed 3,7.As shown in Figure 2, when the 1st fixed 3 and the 1st movable type 1A matched moulds, be formed for accepting the 1st die cavity 2 of the 1st resin.On the other hand, when the 2nd fixed 7 and the 2nd movable type 1B matched moulds, be formed for accepting the 2nd die cavity 6 of the 2nd resin.Fig. 3 means the state after the injection of the 1st resin and the 2nd resin completes, and Fig. 4 means to make movable type 1A, 1B to separate and the state of die sinking again.

The rotating disc 9 that the multilevel shaping facility have fixed disk 8 and can exit rotatably with respect to fixed disk 8.Fixed disk 8 has the 1st fixed 3 and the 2nd fixed 7, and rotating disc 9 has a pair of movable type 1A, 1B.Each of each of a pair of movable type 1A, 1B and the 1st fixed the 3, the 2nd fixed 7 relatively configures, therefore as shown in Figure 2, if by rotating disc 9 during to fixed disk 8 crimping, a pair of movable type 1A, 1B while and the 1st fixed 3 and the 2nd fixed 7 matched moulds, can carry out the injection of the 1st resin and the injection of the 2nd resin simultaneously.

Under state before the matched moulds of Fig. 1, in the 2nd movable type 1B relative with the 2nd fixed 7, maintain the once-forming product F1 (the 1st resin bed 4 and cosmetic sheet 5) that last operation is shaped, in the 2nd fixed 7, configuration remains the decorating film 12 of secondary forming.Here, cosmetic sheet 5 forms intermediate layer.On the other hand, maintain the cosmetic sheet 5 that follow-up once-forming is used in the 1st fixed 3.The multilevel shaping facility are useful on cosmetic sheet 5 are fixed on to the robot device 15 on the 1st fixed 3.

Cosmetic sheet 5 (being intermediate layer, an example of decorative layer) is the resin molded body be shaped in advance matchingly with the shape of the 1st fixed 3, and is trapped in unvaryingly the inside of multilevel shaping product to embed mode between the 1st resin and the 2nd resin.Can be pre-formed various patterns on cosmetic sheet 5, but can be also the colored film etc. that there is no the monochrome of pattern.Cosmetic sheet 5 can consist of various resins such as acrylic resin, polyolefin resins, if but by heat resistances such as polycarbonate resin or PET, high resin forms, for phenomenons such as avoiding the cast gate transfer, more produce effect.The thickness of cosmetic sheet 5 is suitable in the scope of 75-200 μ m, preferably uses 125-150 μ m.

Decorating film 12 (is hot transfer foil, one example of decorative layer) be integrated the forming of base sheet 12b by the ornamental portion 12a with the 1st resin bed or the 2nd resin bed hot adhesion and handling (handling) use, in any operation after ornamental portion 12a and resin bed hot adhesion, base sheet 12b is stripped from.Ornamental portion 12a generally have become final multilevel shaping product outermost peel off protective layer and with the tack coat of resin bed hot adhesion; generally be provided with design layer peeling off between protective layer and tack coat, but can be also the colored film that there is no the monochrome of pattern.

As the material of base sheet 12b, can use the single-layer sheet of selecting or the laminates that the resin of more than two kinds of selection forms from above-mentioned or copolymer sheet etc. from polycarbonate resin, polyamide-based resin, polyimide based resin, polyester resin, acrylic resin, olefine kind resin, polyurethanes resin, acronitrile-butadiene-styrene resinoid etc.In addition, be to improve the fissility of base sheet 12b, also can between base sheet 12b and ornamental portion, form the release layer formed by alkyd amino resinoid etc.As preferred 5～500 μ m of the thickness of base sheet 12b.

As the material of peeling off protective layer, can use acrylic resin, nitrocellulose resinoid, polyurethanes resin, chlorinated rubber resinoid, vinyl chloride-vinyl acetate Copolymer resin, polyamide-based resin, polyester resin, epoxy resin, polycarbonate resin, olefine kind resin, acrylonitrile butadiene styrene resin etc.The thickness of peeling off protective layer is 0.5～50 μ m preferably.

As the material of design layer, also can use and contain resins such as acrylic resin, nitrocellulose resinoid, polyurethanes resin, chlorinated rubber resinoid, vinyl chloride-vinyl acetate Copolymer resin, polyamide-based resin, polyester resin, epoxy resin as adhesive and the coloring printing ink using the pigment of appropriate color or dyestuff as colouring agent.

Tack coat can be selected the material high with the resin compatibility of hot adhesion object.The thickness of tack coat is 0.5～50 μ m preferably.

As shown in Figure 2, when the 1st movable type 1A and the 1st fixed 3 matched moulds, the 1st die cavity 2 of accepting the 1st resin is formed on by between the cosmetic sheet 5 and the 1st movable type 1A of the 1st fixed 3 supportings.Be arranged on the 1st fixed 3 for the 1st cast gate 10 to the 1st die cavity 2 injection the 1st resins.

On the other hand, when the 2nd movable type 1B and the 2nd fixed 7 matched moulds, at the decorating film 12 by the 2nd fixed 7 supportings with between by the cosmetic sheet 5 of the 2nd movable type 1B supporting, be formed with for accepting the 2nd die cavity 6 of the 2nd resin.Be arranged on the 2nd fixed 7 for the 2nd cast gate 11 to the 2nd die cavity 6 injection the 2nd resins.On the 2nd fixed 7, be provided with: the film carrying device 13 of sending decorating film 12; The film coiler device 14 of coiling decorating film 12; Decorating film 12 is crimped on to the rectangular box-like clip 16 of the 2nd fixed 7 one sides.

In addition, the 1st resin and the 2nd resin can be the resins of different colours, can be also the resins of other kinds that other characteristics such as mutual hardness are different.For example, the 1st resin can adopt the mixing of polycarbonate resin, ABS resin or polycarbonate resin and ABS resin etc., and the 2nd resin can adopt PMMA (plexiglass).Especially, when the 1st resin adopts ABS resin and the 2nd resin to adopt PMMA, because the formability of ABS resin is high, can carry out well the multilevel shapings such as two look shapings.And, even the softening temperature of ABS resin is lower than the softening temperature of PMMA, because of the existence of cosmetic sheet 5, while injecting plexiglass, the ABS resin that also can suppress to be shaped is out of shape because of the heat of PMMA.

In addition, if decorating film 12 to peel off protective layer or design layer and the 2nd these both sides of resin be all PMMA, because the surface of two parts is integrated because the heat of PMMA is melt into each other, so need on decorating film 12, tack coat be set.

On movable type 1, be provided with: the slide block 17 (example of fixed cell) that the part of cosmetic sheet 5 is fixed; Accommodate the groove 18 of the essentially rectangular of clip 16 during matched moulds.The details of these structures is as shown in Fig. 5 (the I-I cross section in Fig. 3) and Fig. 6 (the I-I cross section in Fig. 5), and the integral body of cosmetic sheet 5 as shown in Figure 7.As shown in Fig. 7 of the secondary forming product F2 taken off from movable type 1 after solidifying as meaned, one side fixing by aforesaid slide block 17 at 5b，Gai edge, the edge 5b of the protrusion tab 5a that is formed with trapezoidal shape of cosmetic sheet 5.The compensated cavity 19 that can accommodate protrusion tab 5a while in addition, on the 2nd movable type 1B, being formed with the 2nd fixed 7 and movable type 1 matched moulds.In addition, be arranged on the 2nd resin for the 2nd cast gate 11 that injects the 2nd resin and must be injected into by compensated cavity 19 position of the 2nd die cavity 6.

In more detail, when the 2nd movable type 1B and the 2nd fixed 7 matched moulds, between is formed with the connection stream 20 that the 2nd cast gate 11 and the 2nd die cavity 6 are interconnected.Be injected into the 2nd die cavity 6 from the 2nd resin of the 2nd cast gate 11 injections via this connection stream 20.Being communicated with stream 20 has: the 1st circuit portion 21 that arrives the linearity between the clip 16 that approaches side since the 2nd cast gate 11; Around clip 16 and the 2nd circuit portion 22 of roundabout roughly コ word shape; Compensated cavity 19 since the 2nd circuit portion 22 towards the clip 16 in a distant place.As shown in Figure 5, the compensated cavity 19 that can accommodate protrusion tab 5a is the closer to the wider diffusion type of once-forming product F1 amplitude.

Form the result of such connection stream 20, while injecting the 2nd resin, the 2nd resin is always by being started to contact with cosmetic sheet 5 with the space that the 2nd fixed 7 surrounds by protrusion tab 5a.Therefore, even the 2nd resin of high temperature contacts with cosmetic sheet 5, the heat of the 2nd resin is transmitted to cosmetic sheet 5, the heat be subject to due to the cosmetic sheet 5 protrusion tab 5a large by area is to movable type 1 heat release effectively, and cosmetic sheet 5 also can become high temperature hardly, can prevent the melting of cosmetic sheet 5.And, during matched moulds, it is mobile that clip 16 makes slide block 17 slide to protrusion tab 5a mono-thruster with rising, grips thus the edge 5b of protrusion tab 5a by slide block 17 and the 2nd movable type 1B, thus the phenomenon of cosmetic sheet 5 dislocation in the time of also can preventing the injection of the 2nd resin.Thus, because protrusion tab 5a and contacting also of the 2nd movable type 1B can maintain well, so the heat of cosmetic sheet 5 is conducted heat to the 2nd movable type 1B reliably by protrusion tab 5a, and the heat energy of the edge 5b of protrusion tab 5a is enough reliably effectively to the 2nd movable type 1B and slide block 17 heat releases.Thus, can prevent reliably the melting of cosmetic sheet 5.And, can prevent floating or " perk " etc. of cosmetic sheet 5, can manufacture well the multilevel shaping product.

Here, to having used multilevel shaping of the present invention to describe by the concrete manufacture method of the multilevel shaping product (two look formed products) of mould.

In the present embodiment, by robot device 15, the cosmetic sheet 5 be shaped is arranged on the 1st fixed 3.On the other hand, in the 2nd fixed 7, send the decorating film 12 of certain-length by film carrying device 13, simultaneously, by the decorating film 12 of film coiler device 14 coiling certain-lengths, make thus decorating film 12 relative with the 2nd fixed 7 (with reference to Fig. 1).In addition, decorating film 12 is crimped on the edge of the 2nd fixed 7 by clip 16, by heater (not shown) heating decorative film 12, and makes the recess close contact of decorating film 12 and the 2nd fixed 7 by suction device (not shown).Now, on the movable type 1 relative with the 2nd fixed 7, maintain by the 1st resin bed 4 and the once-forming product F1 that forms with the cosmetic sheet 5 of the upper surface hot adhesion of the 1st resin bed 4.

Then, as shown in Figure 2, make rotating disc 9 make the 1st movable type 1A and the 1st fixed 3 matched moulds to fixed disk 8 one side shiftings, and make the 2nd movable type 1B and the 2nd fixed 7 matched moulds.Thus, form the 1st die cavity 2 between the cosmetic sheet 5 by the 1st fixed 3 supportings and the 1st movable type 1A.Meanwhile, be formed with the 2nd die cavity 6 at the decorating film 12 by the 2nd fixed 7 supportings with between by the once-forming product F1 of the 2nd movable type 1B supporting.Simultaneously, the slide block 17 pushed by clip 16 during matched moulds moves to protrusion tab 5a mono-Slideslip, and the part (example of pressure contact portion) of slide block 17 (example of pressure contact portion) and another movable type 1 grips the edge 5b of protrusion tab 5a.As shown in Figure 3, from the 1st resin of the 1st cast gate 10 injection, be injected into the 1st die cavity 2, at the lower surface of cosmetic sheet 5 the 1st resin bed 4 that is shaped, become next once-forming product F1.On the other hand, as shown in Figure 3 and Figure 6, from the 2nd resin of the 2nd cast gate 11 injections, be injected into the 2nd die cavity 6, be shaped by the integrated secondary forming product F2 formed of decorating film 12, once-forming product F1 and the 2nd resin bed 23.

Then, as shown in Figure 4, rotating disc 9 is separated from fixed disk 8, and the movable type 1 that makes both sides is from the 1st fixed 3 and the 2nd fixed 7 die sinkings.By this die sinking, the base sheet 12a of decorating film 12 peels off naturally from ornamental portion 12b, the secondary forming product F2 that the surface that has obtained only having ornamental portion 12b to be transferred to the 2nd resin forms.Therefore, curing secondary forming product F1 is taken out from movable type 1, and make rotating disc 9 Rotate 180 degree.And, by repeatedly carrying out aforesaid operations, the ornamental portion 12b that produces resin bed 4, cosmetic sheet 5, secondary resin bed 23 and a decorating film 12 is stacked gradually the secondary forming product F2 formed.The ornamental portion 12b be transferred on secondary forming product F2 consists of the tack coat with the 2nd resin bed 23 hot adhesions, middle design layer and the outermost protective layer of peeling off.In addition, as finishing step, the utensil of use scissors (scissors) shape etc. cuts off the protrusion tab 5a (with reference to Fig. 7) outstanding to the outside of secondary forming product F2.

(the second embodiment)

In the second embodiment shown in following Fig. 8～Figure 12, main only to the structure from the first embodiment, different structures describes, for identical incomplete structure explanation.

The multilevel shaping mould that the second embodiment is used, as shown in Figure 8, there is the 1st fixed the 33, the 2nd fixed 37 (example of the 2nd mould) and a pair of movable type 31 (example of the 1st mould), with the first embodiment on the contrary, the public type that fixed 33,37 is convex, the parent form that a pair of movable type 31 is concavity.

As shown in Figure 9, when the 1st fixed 33 and the 1st movable type 31A matched moulds, while being formed for accepting the 1st die cavity 32, the 2 fixeds 37 of the 1st resin and the 2nd movable type 31B matched moulds, be formed for accepting the 2nd die cavity 36 of the 2nd resin.

Be formed on compensated cavity 38 on movable type 31 when the 2nd movable type 31B and the 2nd fixed 37 matched moulds, can accommodate the protrusion tab 35a of cosmetic sheet 35.In addition, the 2nd cast gate 39 that injects the 2nd resin is arranged on the 2nd resin and must be injected into by compensated cavity 38 position of the 2nd die cavity 36.

In more detail, as shown in figure 12, when the 2nd movable type 31B and the 2nd fixed 37 matched moulds, between the 2nd movable type 31B and the 2nd fixed 37, be formed with the connection stream 40 that the 2nd cast gate 39 and the 2nd die cavity 36 are interconnected.Be injected into the 2nd die cavity 36 from the 2nd resin of the 2nd cast gate 39 injections via this connection stream 40.Being communicated with stream 40 has: the 1st circuit portion 41 that arrives the linearity between the clip 16 that approaches side since the 2nd cast gate 39; Around clip 16 and the 2nd circuit portion 42 of roundabout roughly コ word shape; Compensated cavity 38 since the 2nd circuit portion 42 towards the clip 16 in a distant place.With the compensated cavity 19 of the 1st embodiment similarly, the compensated cavity 38 that can accommodate protrusion tab 35a is the diffusion type that amplitude broadens towards once-forming product F1 gradually from the 2nd circuit portion 42.

Form the result of such connection stream 40, while injecting the 2nd resin, the 2nd resin always contacts with cosmetic sheet 35 by the space surrounded with the 2nd fixed 37 by protrusion tab 35a.Therefore, even the 2nd resin of high temperature contacts with cosmetic sheet 35, the heat of the 2nd resin is transmitted to cosmetic sheet 35, the heat be subject to due to the cosmetic sheet 35 protrusion tab 35a large by area is effectively to movable type 31 heat releases, so cosmetic sheet 35 can become high temperature hardly, also can prevent the melting of cosmetic sheet 35 and the distortion of pattern.And, during matched moulds, owing to gripping the edge 35b of protrusion tab 35a between slide block 17 and the 2nd movable type 31B, so the phenomenon of cosmetic sheet 35 dislocation in the time of also can preventing the injection of the 2nd resin.Thus, because protrusion tab 35a is maintained well with the 2nd contacting also of movable type 31B, so the heat of cosmetic sheet 35 is transmitted to the 2nd movable type 31B reliably by protrusion tab 53a, and the heat of the edge 35b of protrusion tab 35a is reliably effectively to movable type 31 and slide block 17 heat releases.Thus, can prevent reliably the melting of cosmetic sheet 35.And, can prevent floating or " perk " etc. of cosmetic sheet 35, can manufacture well the multilevel shaping product.

Below, the concrete manufacture method of the multilevel shaping product in the 2nd embodiment is described.

In the present embodiment, as shown in Figure 8, in the 1st movable type 31A, send the decorating film 12 of certain-length by film carrying device 13, simultaneously, by the decorating film 12 of film coiler device 14 coiling certain-lengths, make thus decorating film 12 and the 1st movably mould 31A relative, be crimped on the edge of type 31A by clip 16, and pass through heater heating decorative film 12, and make the recess close contact of decorating film 12 and the 1st movable type 31A by suction device.Now, on 1st fixed 33 relative with the 1st movable type 31A, by robot device 15, maintain cosmetic sheet 35.On another movable type 31, maintain the once-forming product F1 (the 1st resin bed 34 and cosmetic sheet 35) that last operation is shaped.

Below, as shown in Figure 9, make rotating disc 9 to fixed disk 8 one side shiftings, and make the 1st movable type 31A and the 1st fixed 33 matched moulds, and make the 2nd movable type 31B and the 2nd fixed 37 matched moulds.Thus, form the 1st die cavity 32 at the decorating film 12 by the 1st movable type 31A supporting with between by the cosmetic sheet 35 of the 1st fixed 33 supportings.Simultaneously, form the 2nd die cavity 36 between the once-forming product F1 by the 2nd movable type 31B supporting and the 2nd fixed 37.During this matched moulds, the slide block 17 be urged by clip 16 moves to protrusion tab 35a mono-Slideslip, and the part (example of pressure contact portion) of slide block 17 (example of pressure contact portion) and another movable type 31 grips the edge 35b of protrusion tab 35a thus.As shown in figure 10, from the 1st resin of the 1st cast gate 49 injections, be injected into the 1st die cavity 32, the resin bed 34 that is shaped a time between decorating film 12 and cosmetic sheet 35, obtain once-forming product F1.On the other hand, as shown in Figure 10 and Figure 12, from the 2nd resin of the 2nd cast gate 39 injections, be injected into the 2nd die cavity 36, obtain once-forming product F1 and the integrated formed products formed of the 2nd resin bed 43.

Then, as shown in figure 11, rotating disc 9 is separated from fixed disk 8, and the movable type 31 that makes both sides is from the 1st fixed 33 and the 2nd fixed 37 die sinkings.By this die sinking, naturally peeled off the secondary forming product F2 that obtains only having ornamental portion 12 to be transferred to and form on the surface of a resin bed 34 by the base sheet 12a of the decorating film 12 of the secondary forming product F2 of the 2nd fixed 37 supporting.Therefore, curing secondary forming product F2 is taken off from movable type 1, make rotating disc 19 Rotate 180 degree.And, by repeatedly carrying out aforesaid operations, the ornamental portion 12b that produces secondary resin bed 34, cosmetic sheet 35, resin bed 34 and decorating film 12 stacks gradually the secondary forming product F2 formed.

(the 3rd embodiment)

The multilevel shaping mould that the 3rd embodiment is used, as shown in Figure 13～Figure 18, have a pair of movable type 51A, 51B (example of the 1st mould), the 1st fixed 52 and the 2nd fixed 53 (example of the 2nd mould).Figure 13～Figure 18 has meaned to inject the state after the 1st resin and the 2nd resin.The 3rd embodiment is only used cosmetic sheet 56 and does not use the example of decorating film 12.Although not shown, with above-mentioned embodiment similarly, a pair of movable type 51A, 51B be rotated the dish 9 the supporting, the 1st fixed 52 and the 2nd fixed 53 be fixed the dish 8 the supporting.

While maintaining the 1st fixed 52 of cosmetic sheet 56 and the 1st movable type 51A matched moulds, form the 1st die cavity 54 between cosmetic sheet 56 and the 1st movable type 51A.Figure 14 and Figure 15 mean that the 1st resin (55) is injected into the 1st die cavity 54 and obtains the state of once-forming product F1.

On the other hand, while maintaining in last operation the 2nd movable type 51B matched moulds to the 2 fixed 53 of the once-forming product F1 that is injected into/is shaped, form the 2nd die cavity 64 between the cosmetic sheet 56 of once-forming product F1 and the 2nd fixed 53.Figure 17 and Figure 18 mean that the 2nd resin 65 is injected into the 2nd die cavity 64 and obtains the state of secondary forming product F2.

As shown in figure 18, between movable type 51 and the 2nd fixed 53, be formed with the compensated cavity 71 of the protrusion tab 56a that can accommodate cosmetic sheet 56, be arranged on the 2nd resin for the 2nd cast gate 66 that injects the 2nd resin and must be injected into by compensated cavity 71 position of the 2nd die cavity 64.

As shown in figure 13, the protrusion tab 56a of cosmetic sheet 56 is the outstanding oblong-shaped of roughly whole amplitude range on the long limit of the side from cosmetic sheet 56.As the II-II cross section in Figure 13 is as shown in Figure 14, between the die joint 51a and protuberance 51b of the 1st movable type 51A, along a long limit of protuberance 51, be formed with the groove 63 that cross section is V word shape.On the other hand, between the die joint 52a and recess 52b of the 1st fixed 52, be formed with the ridge 62 that the cross section entered to groove 63 is V word shape.Therefore, when the 1st movable type 51A and the 1st fixed 52 matched moulds, one side 62a of ridge 62 and a side 63a of groove 63 contact, simultaneously, the protrusion tab 56a of another side 63b (example of pressure contact portion) of another side 62b (example of pressure contact portion) by ridge 62 and groove 63 clamping cosmetic sheet 56.

I-I cross section in Figure 13, Figure 14 and Figure 13 is as shown in Figure 15, when the 1st movable type 51A and the 1st fixed 52 matched moulds, between the 1st movable type 51A and the 1st fixed 52, is formed with the 1st connection stream 61 that the 1st cast gate 57 and the 1st die cavity 54 are communicated with.Be injected into the 1st die cavity 54 from the 1st resin of the 1st cast gate 57 injections via the 1st connection stream 61.The 1st is communicated with stream 61 has: the 1st circuit portion 58 of the linearity formed between the die joint 52a of the die joint 51a of the 1st movable type 51A and the 1st fixed 52; The 2nd circuit portion 59 of the linearity formed between a side 63a of a side 62a of ridge 62 and groove 63; The 3rd circuit portion 60 formed between another side 63b of another side 62b of ridge 62 and groove 63.The 3rd circuit portion 60 is the diffusion type that amplitude broadens towards once-forming product F1 gradually from the 2nd circuit portion 59.The 2nd circuit portion 59 connects with bending with respect to the 1st circuit portion 58, and the 3rd circuit portion 60 also connects with bending with respect to the 2nd circuit portion 59.

On the other hand, as the IV-IV cross section in Figure 16 is as shown in Figure 17, between the die joint 53a and recess 53b of the 2nd fixed 53, be formed with the ridge 72 of the V word shape entered to groove 63.When the 2nd movable type 51B and the 2nd fixed 53 matched moulds, one side 72a of ridge 72 and a side 63a of groove 63 contact, simultaneously, the protrusion tab 56a of another side 63b (example of pressure contact portion) of another side 72b (example of pressure contact portion) by ridge 72 and groove 63 clamping cosmetic sheet 56.

III-III cross section in Figure 16, Figure 17 and Figure 16 is as shown in Figure 18, when the 2nd movable type 51B and the 2nd fixed 53 matched moulds, between the 2nd movable type 51B and the 2nd fixed 53, be formed with the 2nd connection stream 70 that the 2nd cast gate 66 and the 2nd die cavity 64 are interconnected.Be injected into the 2nd die cavity 64 from the 2nd resin of the 2nd cast gate 66 injections via the 2nd connection stream 70.The 2nd is communicated with stream 70 has: the 1st circuit portion 67 of the linearity formed between the die joint 53a of the die joint 51a of the 2nd movable type 51B and the 2nd fixed 53; The 2nd circuit portion 68 of the linearity formed between a side 63a of a side 72a of ridge 72 and groove 63; The 3rd circuit portion 69 formed between another side 63b of another side 72b of ridge 72 and groove 63.The 3rd circuit portion 69 is the diffusion type that amplitude broadens towards once-forming product F1 gradually from the 2nd circuit portion 68.The 2nd circuit portion 68 connects with bending with respect to the 1st circuit portion 67, and the 3rd circuit portion 69 also connects with bending with respect to the 2nd circuit portion 68.Between another side 63b of another side 72b of ridge 72 and groove 63, be formed with the compensated cavity 71 of the part of the protrusion tab 56a that can accommodate cosmetic sheet 56.Here, the 3rd circuit portion 69 of exposing for a part that is formed on the protrusion tab 56a on cosmetic sheet 56 forms compensated cavity 71.

Form the result of such connection stream 40, while injecting the 2nd resin, the 2nd resin always contacts with cosmetic sheet 56 by the space of near the protrusion tab 56a by compensated cavity 71 and the 2nd fixed 53 encirclements.Therefore, even the 2nd resin of high temperature contacts with cosmetic sheet 56, the heat of the 2nd resin is conducted heat to cosmetic sheet 56, the heat be subject to due to the cosmetic sheet 56 protrusion tab 56a large by area is effectively to movable type 51 heat releases, so cosmetic sheet 56 can become high temperature hardly, also can prevent the melting of cosmetic sheet 56.

And, during matched moulds, as shown in FIG. 13 and 14, in protrusion tab 56a not and overlapping two side portions 56c, the 56d of the 3rd circuit portion 60 be clamped and fixed between the 1st movable type 51A and the 1st fixed 52.Thus, inject the 1st resins from the 1st cast gate 57 to the 1st die cavity 54 and when the lower surface of cosmetic sheet 56 is shaped once-forming product 55, the 1st resin can not enter the gap between the side 62b of opposite side.

In addition, about the 2nd fixed 53 and the 2nd movable type 51B, as shown in FIG. 16 and 17, in protrusion tab 56a not and overlapping two side portions 56f, the 56g of the 3rd circuit portion 69 be clamped and fixed between movable type 51 and the 2nd fixed 53.Thus, to the 2nd die cavity 64, inject from the 2nd resin of the 2nd cast gate 66 injections and when the upper surface of cosmetic sheet 56 is shaped secondary forming product F2, the 2nd resin also can not enter the gap between the side 63b of opposite side.

Then, the 2nd movable type 51B and the 2nd fixed 53 are carried out to die sinking, secondary forming product F2 is taken off from the 2nd movable type 51B.In addition, during fine finishining, cut off the ledge (with reference to Figure 19) of outstanding protrusion tab 56a, the 1st formed products 55 and the 2nd formed products 65 to outside of the secondary forming product F2 that takes out from movable type 51.Now, because the long limit from a side in secondary forming product F2 is extruded with the ledge of protrusion tab 56a, the 1st formed products 55 and the 2nd formed products 65, so only just can complete etc. by once cutting off, can realize reduction and the productive raising of operation.In addition, due to by the 1st movable type 51A and the 1st fixed 52 and the 2nd movable type 51B and the 2nd fixed 53 clamping protrusion tab 56a, so do not need to arrange in addition the structure etc. of clamping protrusion tab 56a, simplification that can implementation structure.And, a plurality of cast gates also can be set and repeatedly implement.

(the 4th embodiment)

In the 4th embodiment shown in following Figure 22～Figure 29, main only to the structure from the first embodiment, different structures describes, about identical incomplete structure explanation.

Figure 29 (a) illustrates in general the outward appearance of the product that complete from eliminating unwanted part by this multilevel shaping with the secondary forming product F2 of Mold Making and obtaining.From the Figure 29 (b) in the B-B cross section that means Figure 29 (a), by this multilevel shaping with the secondary forming product F2 of Mold Making there is the 1st the most inboard resin bed 44, be positioned at the cosmetic sheet 45 (example in intermediate layer) in the outside of the 1st resin bed 44, the 2nd resin bed 23 outside it and be positioned at outermost decorating film 12.

The 1st resin bed 44 is opaque, is formed with the window of rectangle near in the central.Do not form window on cosmetic sheet 45, the 2nd resin bed 23 and decorating film 12, but formed by transparent resin.Therefore, these secondary forming product F2 is applicable in the situation such as the display board of mobile phone etc., can be from the rectangular window perspective liquid crystal panel (not shown) of the 1st resin bed 44 etc.

As shown in figure 22, the multilevel shaping that the 4th embodiment is used has the 1st fixed 182 and the 2nd fixed 183 (being all an example of the 2nd mould) of dish 8 supportings that are fixed with mould and is rotated a pair of movable type 181A, the 181B (example of the 1st mould) of dish 9 supportings.Rotating disc 9 is configured to respect to fixed disk 8 and can rotates and can exit.Here, fixed the 182, the 183rd, the parent form of concavity, a pair of movable type 181A, 181B are the public types of convex.

In Figure 22, at the recess of the 1st fixed 182, engaging has the cosmetic sheet 45 of making by electroforming in advance, in the recess arrangement of the 2nd fixed 183, decorating film 12 is arranged, and can be fixed by clip 16.

On the other hand, the once-forming product F1 that has last operation to obtain in the protuberance engaging of the 2nd movable type 181B.These once-forming product F1 has the shape identical with the once-forming product F1 shown in Figure 24.

In addition, Figure 22 only show the recess at the 2nd fixed 183 in clip 16 above fixedly decorating film 12 position and fix its Zhe Liangge position, position below recess, but in fact, as Figure 28 is illustrative, due to clip 16 rectangular frame shape roughly, thus can be in the all-round scope of the edge of the rectangle of the recess that surrounds the 2nd fixed 183 fixing decorating film 12.The structure relevant to this clip 16 is general in all embodiments of this specification record.

Below, as shown in figure 23, make rotating disc 9 when fixed disk 8 crimping, the 1st fixed 182 and the 1st movable type 181A are by matched moulds, and simultaneously, the 2nd fixed 183 and the 2nd movable type 181B are by matched moulds.

In the matched moulds of the 1st fixed 182 and the 1st movable type 181A, as shown in the top of Figure 23, and the cosmetic sheet 45 and the 1st movable type 181A of the 1st fixed 182 engagings between, be formed with the 1st die cavity 132 of accepting the 1st resin.If inject the 1st resin to the 1st die cavity 132, the 1st resin hot adhesion, at the inner surface of cosmetic sheet 45, obtains the once-forming product F1 (example of the 1st operation) consisted of cosmetic sheet 45 and the 1st resin bed 44.Figure 23 shows the state that has injected the 1st resin bed 44.

On the other hand, as shown in the bottom of Figure 23, in the matched moulds of the 2nd fixed 183 and the 2nd movable type 181B, and the once-forming product F1 of the 2nd movable type 181B engaging and and the decorating film 12 of the 2nd fixed 183 engagings between, be formed with the 2nd die cavity 136, to it, inject the 2nd a resin (example of the 2nd operation; In addition, there is shown the 2nd resin bed 23 be injected into).In fact, before injecting the 2nd resin, decorating film 12 is attracted to the inner surface of the recess of the 2nd fixed 183.For realizing this absorption, at the recess of the 2nd fixed 183, be provided with a large amount of trickle attraction holes (not shown) and by attracting hole to make the recess inner surface of the 2nd fixed 183 produce the drawdown pump (not shown) of negative pressure.In addition, such adsorbing mechanism also is arranged between the 1st fixed 182 and once-forming product F1.

As the enlarged drawing of the major part of Figure 23 is as shown in Figure 26～27, be formed with two protrusion tabs on cosmetic sheet 45.One of them is to extend the 1st protrusion tab 45a formed with linearity from the part of the edge on 4 limits of cosmetic sheet 45, another be from the part of opposition side outwardly-bent the 2nd protrusion tab 45b that forms.Between the forming process shown in Figure 22 and Figure 23, the 1st protrusion tab 45a is crimped on the inner surface of the 1st fixed 182 together with the 2nd protrusion tab 45b.In addition, as shown in figure 29, from final secondary forming product F2 excision protrusion tab 45a, 45b.

As shown in figure 27, the 1st protrusion tab 45a is when the 2nd fixed 183 and the 2nd movable type 181B matched moulds, is housed in the 1st compensated cavity 136a that is formed at the 2nd movable type 181B.

In addition, the zone that is arranged on for the 2nd cast gate 139 that injects the 2nd resin the 1st compensated cavity 136a that the 2nd resin must be by having the 1st protrusion tab 45a is injected into the 2nd such position of die cavity 136.

As shown in figure 26, the 2nd protrusion tab 45b, when the 1st fixed 182 and the 1st movable type 181A matched moulds, is housed in the part of the 2nd compensated cavity 132a that is formed at the 1st movable type 181A.

When the 1st resin be injected in the operation shown in Figure 23 and curing the completing of the 2nd resin, as shown in figure 24, rotating disc 9 is pulled out and separates from fixed disk 8, makes thus a pair of movable type 181A, 181B respectively from the 1st fixed the 182, the 2nd fixed 183 die sinkings.

Under this state, at the protuberance upper support of the 1st movable type 181A, the once-forming product F1 be shaped is arranged, at the protuberance upper support of the 2nd movable type 181B, the secondary forming product F2 be shaped is arranged.

Take off secondary forming product F2 from the 2nd fixed 183, as shown in figure 25, by making rotating disc 9 Rotate 180s °, can repeatedly carry out the operation started from Figure 22 thus.

When the excision operation etc. of the secondary forming product F2 taken off of Figure 24 being carried out to protrusion tab 45a, 45b is processed, obtain the secondary forming product F2 (completing product) of the outward appearance shown in Figure 29.

Here, be described in detail then to the operation of Figure 22 and Figure 23.

At first, as shown in Figure 23 and Figure 26, by the matched moulds of the 1st fixed 182 and the 1st movable type 181A, between amphitypy 182,181A, be formed with the connection stream 140 that the 1st cast gate 138 and the 1st die cavity 132 are interconnected.Being communicated with stream 140 consists of following part: the 1st circuit portion 140A of the linearity directly be communicated with the outlet of the 1st cast gate 138; The 2nd circuit portion 140B of the linearity directly be communicated with the 1st die cavity 132.The mutual almost parallel of the 2nd circuit portion 140B and the 1st circuit portion 140A extends, but mutually with the bent axle shape, links.The inner surface of the 1st fixed 182 of working as at the borderline phase with its link, be formed with approach axis along the 1st resin towards fixed disk 8 sides the 182X of resignation section with step-like introducing.And the front end of the 2nd protrusion tab 45b of cosmetic sheet 45 configures relatively in the mode that is crimped on the 182X of this resignation section, prevent thus the floating or " perk " etc. of the mobile cosmetic sheet caused 45 of the 1st resin.The 182X of resignation section has the degree of depth larger than the thickness of cosmetic sheet 45.

Below, as shown in Figure 23 and Figure 27, by the matched moulds of the 2nd fixed 183 and the 2nd movable type 181B, between amphitypy 183,181B, be formed with the connection stream 142 that the 2nd cast gate 139 and the 2nd die cavity 136 are interconnected.Being communicated with stream 142 consists of following part: the 1st circuit portion 142A that forms and arrive from the 2nd cast gate 139 linearity between the clip 16 that approaches side by the 2nd compensated cavity 136a; Side 16b along the below of clip 16 approaches the 2nd circuit portion 142B that rotating disc 9 ground enter; The 3rd circuit portion 142C that extend top along from the upper surface 16c of clip 16 to figure; The 4th circuit portion 142D approached to the 2nd fixed 183 along the side 16d of the top of clip 16.

Due to the final position that is communicated with stream 142 the 4th circuit portion 142D towards the 2nd fixed 183 along the substantial transverse extension in figure, so, on the boundary face between the 2nd fixed 183 and the 2nd movable type 181B, the inlet portion of the terminal part of the 4th circuit portion 142D (in the face of an example of the position of the stream of protrusion tab) and the 2nd die cavity 136 angularly is not connected with linearity roughly mutually.Particularly, the base end part by the side 16d of top in figure of the clip shown in Figure 27 16 is in the position consistency of the end face of illustrated S point and final secondary forming product F2.

At the 4th circuit portion 142D, be formed with along the approach axis of the 2nd resin the 142X of resignation section (example of stair-stepping recess) with step-like introducing near the center line of the 2nd movable type 181B.And the front end of the 1st protrusion tab 45a of cosmetic sheet 45 configures relatively in the mode that is crimped on the 142X of this resignation section, prevent thus the floating or " perk " etc. of the mobile cosmetic sheet caused 45 of the 2nd resin.The 142X of resignation section has the degree of depth larger than the thickness of cosmetic sheet 45.

Form like this result that is communicated with stream 142, while injecting the 2nd resin, the 2nd resin always contacts with the cosmetic sheet 45 in the 2nd die cavity 136 by the space by the 1st protrusion tab 45a and clip 16 clampings.Therefore, even the 2nd resin of high temperature contacts with cosmetic sheet 45, the heat of the 2nd resin is conducted heat to cosmetic sheet 45, the heat that cosmetic sheet 45 is subject to also can be passed through along the approach axis of the 2nd resin the protrusion tab 45a of the wide diffusion shape of horizontal stroke effectively to the 2nd movable type 181B heat release, thereby the cosmetic sheet 45 in the 2nd die cavity 136 can become high temperature hardly, can prevent from being loaded into the melting of main body section of cosmetic sheet 45 of final secondary forming product F2 and the distortion of pattern etc.In addition, because the 1st protrusion tab 45a becomes diffusion shape, so heat that the 1st protrusion tab 45a from the 2nd resin to cosmetic sheet 45 transmits, at first along the width of the 1st protrusion tab 45a, expand, to the main body transmission of the cosmetic sheet 45 beyond the 1st protrusion tab 45a, also can prevent that thus the part of cosmetic sheet 45 from becoming the phenomenon of high temperature again.

In addition, as previously mentioned, because the entrance of the terminal part of the 4th circuit portion 142D and the 2nd die cavity 136 angularly is not connected with linearity roughly mutually, so, the state that the 2nd resin injected from the 2nd cast gate 139 in the 2nd operation is connected along die cavity 135 and this die cavity 135 at the 4th circuit portion 142D towards the 1st protrusion tab 45a, be injected into along the bearing of trend of the 1st protrusion tab 45a.That is, now, the 2nd resin not with the 1st protrusion tab 45a of cosmetic sheet 45 and the main body section head-on crash ground of packing secondary forming product F2 into final contiguously, flow swimmingly and enter the 2nd die cavity 136 along this main body section of cosmetic sheet 45.Therefore, contacting with the 2nd resin injected from the 2nd cast gate 139 structure that one side enters the 2nd die cavity 136 on one side with cosmetic sheet 45 head-on crash ground compares, the 2nd resin can be near cosmetic sheet 45 the generation precipitation, thereby cosmetic sheet 45 more is difficult to be subject to the impact of the heat of the 2nd resin.

And, as previously mentioned, the position consistency of the end face of the base end part by the side 16d of top in figure of the clip 16 shown in Figure 27 and final secondary forming product F2.; decorating film 12 is crimped to the position at the position of the main part that is about to become the final secondary forming product of being loaded into of decorating film 12 P2 to the 2nd fixed 183 by clip 16, thereby the phenomenon that decorating film 12 floats from the recess inner surface of the 2nd fixed 183 is also suppressed.

(its embodiment)

(1) in the respective embodiments described above exemplified with following structure: protrusion tab 5a, the 35a, the 56a that make to be formed on cosmetic sheet 5,35,56 contact with the mould 1,31,51 of maintenance resin bed 4,34,55 and cosmetic sheet 5,35,56, by by protrusion tab 5a, 35a, 56a and the space that other moulds 7,37,53 that combine with mould 1,31,51 press from both sides, injecting the 2nd resin.But, also can replace these structures, adopt following structure: the outstanding protrusion tab in outside formed to secondary forming product F2 at the 1st resin bed 4,34,55 in advance, the protrusion tab of the 1st resin bed 4,34,55 is contacted with the mould 1,31,51 that keeps the 1st resin bed 4,34,55 and cosmetic sheet 5,35,56, and by by protrusion tab, with the space that other moulds 7,37,53 that combine with mould 1,31,51 press from both sides, injecting the 2nd resin.

(2) in the respective embodiments described above exemplified with following structure: a surface of the 1st resin bed 4,34,55 be shaped in the injection by the 1st resin in advance arranges cosmetic sheet 5,35,56, and manufactures secondary forming product F2 with surfaces the 1st resin bed 4,34,55 opposition sides by the injection of carrying out the 2nd resin cosmetic sheet 5,35,56.But, the invention is not restricted to this structure, for example, can be also injection that the 2nd resin is carried out on a surface of the once-forming product that are shaped in the injection by the 1st resin secondary forming product that are shaped, and on a surface of secondary forming product, cosmetic sheet is set, manufacture the three-layer forming product on the surface with secondary forming product opposition side of this cosmetic sheet by the injection of carrying out the 3rd resin.The resin injection that importantly, can be applicable to carry out multilayer is manufactured the method for multilevel shaping product.

(3) in the respective embodiments described above, the structure that is cosmetic sheet 5,35,56 exemplified with decorative layer, but also can replace such structure, and the structure that is decorating film as decorative layer, protrusion tab that will be outstanding to the outside of multilevel shaping product is formed at this decorating film.

(4) in the respective embodiments described above, the structure of decorating film 12 (hot transfer foil) is set exemplified with the outer surface at secondary forming product F1, but also can replaces such structure, also the outer surface at secondary forming product F1 arranges cosmetic sheet.

(5) in the respective embodiments described above, the structure of the 1st resin bed 4,34,55 is set exemplified with the surface of the opposite side in cosmetic sheet 5,35,56, but also can be at the 1st resin bed 4,34, the 55 moulding integratedly fitting portion chimeric with the framework of mobile phone for example.And, also can decorating film or cosmetic sheet be set on the surface of the opposite side of the 1st resin bed 4,34,55.

(6) in first, second embodiment, be the structure of slide block 17 of the edge 5b of clamping cosmetic sheet 5 exemplified with fixed cell, but be not limited to such structure, for example fixed cell can be also the attraction unit that attracts edge 5b.

(7) in the above-described first embodiment, exemplified with following multilevel shaping machine: it has: rotating disc 9, there is a pair of movable type 1, and can be along laterally exiting and can rotating around the axle core along horizontal; Fixed disk 8, have the 1st fixed 3 and the 2nd fixed 7.But, be not limited to such multilevel shaping machine, for example, also can implement by the mode of using following multilevel shaping machine: it has: the 1st movable plate has movable type, and can exit along the vertical direction; The 2nd movable plate, have the 1st fixed and the 2nd fixed, and can be along horizontal slip.Or following multilevel shaping machine: it has: movable plate, there is movable type, and can be along laterally exiting; Rotating disc, be equipped with the 1st fixed and the 2nd fixed in back-to-back mode, and can be around axle core rotation along the vertical direction.

(8) variation as the 3rd embodiment can be also, for example, as Figure 20, shown in Figure 21, between the die joint 51a and protuberance 51b of movable type 51, be formed with the rake 73 of movable type 51 sides, between the die joint 52a and recess 52b of the 1st fixed 52, be formed with the rake 74 of 1st fixed 52 sides relative with rake 73, between the die joint 53a and recess 53b of the 2nd fixed 53, be formed with the rake 75 of 2nd fixed 53 sides relative with rake 73, between movable type 51 and the 1st fixed 52, be formed with for the 1st of the 1st resin injection the 1st die cavity 54 from the 1st cast gate 57 injections and be communicated with stream 76, between movable type 51 and the 2nd fixed 53, be formed with for the 2nd of the 2nd resin injection the 2nd die cavity 64 from the 2nd cast gate 66 injections and be communicated with stream 77.

So far, using and used two looks shapings of two kinds of resins that color is mutual different to be illustrated as embodiment, but it must be different colors that the resin that the resin that once-forming is used and secondary forming are used does not need, can be also that for example both sides use the resin with transparent same color, clip the multilevel shaping of cosmetic sheet between these resins.And the resin that the resin of using as once-forming and secondary forming are used also can be used all identical resins of kind, color.

Industrial applicibility

The technology of following multilevel shaping can be provided to industry: when in the die cavity of another surface configuration in the intermediate layer with the 1st resin bed hot adhesion, resin by injection forms the 2nd resin bed, the cast gate that can suppress intermediate layer shifts or the melting again of once-forming product.

The explanation of Reference numeral

1,31,51,181 movable types

3,33,52,182 the 1st fixeds

7,37,53,183 the 2nd fixeds

2,32,54,132 the 1st die cavitys

6,36,64,136 the 2nd die cavitys

4,34,44 the 1st resin beds

23,43 the 2nd resin beds

5,35,56 cosmetic sheet (decorative layer, intermediate layer)

5a, 35a, 45a, 45b, 56a protrusion tab

5b, 35b edge

11,39,66,138,139 cast gates

12 decorating films (decorative layer)

16 clips

17 fixed cells

19,38,71,132a, 136a compensated cavity

142X resignation section (stair-stepping recess)

F1 once-forming product

F2 secondary forming product

Claims (9)

1. the manufacture method of multilevel shaping product, these multilevel shaping product have and clip the decorative layer consisted of resin and the 1st resin bed and the 2nd resin bed configured, and its manufacture method is characterised in that,

Have:

The 1st operation, the once-forming product that provide described the 1st resin bed hot adhesion to form on a surface of described decorative layer in this operation;

The 2nd operation forms described the 2nd resin bed to another the surperficial die cavity resin by injection that is configured in described decorative layer in this operation,

At the peripheral part of described decorative layer, be formed with outstanding to the outside of multilevel shaping product and with the protrusion tab of the support type butt of described once-forming product,

In described the 2nd operation, described resin is injected into described die cavity via the stream towards described protrusion tab.

2. manufacture method as claimed in claim 1, is characterized in that,

In described the 2nd operation, carry out the injection of described resin under the state of the edge of having fixed described protrusion tab.

3. manufacture method as claimed in claim 1, is characterized in that,

In described the 2nd operation, under the state be connected with this die cavity along described die cavity at the described stream towards described protrusion tab, along the bearing of trend resin by injection of described protrusion tab.

4. manufacture method as described as any one in claim 1～3, is characterized in that,

In described the 2nd operation, keep out of the way under the state that is arranged on the stair-stepping recess on described support type resin by injection at the front end of the described protrusion tab that is formed at described decorative layer.

5. a die set, it is used in following multilevel shaping product: has and clips the decorative layer formed by resin and the 1st resin bed and the 2nd resin bed configured is characterized in that,

Have: the 1st mould, its once-forming product that can form on a surface of described decorative layer described the 1st resin bed hot adhesion are supported; The 2nd mould, it is formed for the die cavity of described the 2nd resin bed in another face side of described decorative layer,

Described the 1st mould has support, and this support, when described the 1st mould and described the 2nd mould matched moulds, is supported the protrusion tab of the peripheral part that is formed on described decorative layer,

Be configured to comprise the position towards described protrusion tab for the stream to described die cavity resin by injection.

6. die set as claimed in claim 5, is characterized in that,

Fixed cell with edge of fixing described protrusion tab.

7. die set as claimed in claim 6, is characterized in that,

Described fixed cell is that the mode to grip described edge based on described matched moulds is arranged on the pressure contact portion on described the 1st mould and described the 2nd mould.

8. die set as claimed in claim 5, is characterized in that,

Inlet portion towards the position of the described stream of described protrusion tab with respect to described die cavity connects with linearity.

9. die set as described as any one in claim 5～8, is characterized in that,

Stair-stepping recess for the front end of the described protrusion tab of accepting to be formed at described decorative layer, be arranged on described the 1st mould.

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